山地电动单轨运输机系统自主充电-制动设计与试验

Design and Experiment of Autonomous Charging-Braking for Mountain Electric Monorail Transport System

摘要:

针对山地果园单轨运输中补能效率低与制动可靠性不足问题，本研究设计了一种集自主定位取电与高可靠制动于一体的电动单轨运输机系统。基于山地果园运输工况，提出系统总体结构方案，包含楔形取电装置、定位供电装置、双鼓刹制动装置与道岔等关键单元，并阐明其协同机理。为验证制动性能，建立双鼓刹与常用单鼓刹多体动力学ADAMS仿真模型，比较紧急制动响应;进行双鼓刹ANSYS热-结构耦合分析，模拟紧急与持续制动下温度场与应力场。仿真结果表明所设计双鼓刹在1.3 s内刹停，显著短于单鼓刹的2.29 s，紧急工况表现优良，极限持续制动时长为112 s。实际试验结果表明运输机在45°坡度稳定停驻，道岔平均换轨时间为9.327 s。自主充电粗定位误差10~80 mm，精定位误差0.5~2 mm，角度偏差小于2°，可实现精准对接。供电站充电效率92%，输出电流18~22 A（±10%），设备表面温度不大于60℃，适用于户外补能场景。补能操作平均耗时60 s，优于人工充电器25 min。在额定载重、行驶速度0.53 m/s下坡紧急制动时，制动距离423 mm、制动时间1.29 s，优于单鼓刹（803 mm、2.23 s）。研究结果表明系统关键指标达到设计要求，可有效提升补能效率与制动安全性，并为工程化提供参考。

Abstract:

Aiming to address the problems of low energy replenishment efficiency and insufficient braking reliability in monorail transport systems for mountainous orchards, an electric monorail transporter integrating autonomous power pickup and high-reliability braking was proposed. Based on typical orchard operating conditions, an overall system configuration was developed, including a wedge-type power pickup device, a positioning power supply unit, a dual drum brake, and a turnout mechanism. The cooperative working principles of the key components were analyzed. Multibody dynamic models of the dual drum brake and a conventional single drum brake were established in ADAMS to evaluate emergency braking performance, and a thermo-structural coupled analysis was conducted in ANSYS to investigate temperature and stress under emergency and continuous braking conditions. Simulation results indicated that the dual drum brake achieved a full stop within 1.3 s, significantly shorter than that of the single drum brake. Experimental results showed that the transporter can stably park on a 45° half-slope, with an average turnout switching time of 9.327 s. Autonomous charging achieved high positioning accuracy, with fine positioning errors below 2 mm. The charging station exhibited a charging efficiency of 92% and stable output performance. The proposed system effectively improved both energy replenishment efficiency and braking safety, providing technical support for practical applications.